砂带磨工具系统刚柔混合非线性动力学及高精磨削质量预控方法

To satisfy the demand of high precision manufacturing of blades used in aero engines and ships, the abrasive belt tool system, which includes high speed abrasive belt , flexural contact wheel and others rigid wheels, will be studied in this project. The nonlinear dynamic characters and their control methods of this rigid- flexural mixed system will be researched. The dynamic deformation of the abrasive belt tool system results in time-varying, non-uniform distribution of process parameters such as tension, speed, pressure etc.. The influence mechanism and rules of this effect on grinding precision, surface quality and performance deterioration of abrasive belt will be discussed.. The transverse, longitudinal, lateral coupled dynamics model of high speed abrasive belt in a tool system including flexural wheel and special-shaped wheels will be built. The influence rules and compensation methods of the change of grinding depth induced by the dynamic behaviors of the tool system will be obtained. The regulating methods of roughness, residual stress and texture of the grinded surface based on the dynamics of the tool system will be proposed. The optimal control method of the tool system to retard the performance deterioration of abrasive belt will be gotten. The high precision prediction and control method of grinding quality considering the dynamics of the tool system will be proposed finally.. The work proposed in this project can improve and stabilize the grinding quality ，and can also promote the development of the high precision abrasive belt process and equipment. Thus this project has important theoretical and practical value.

面向航空发动机叶片、船用螺旋桨等叶片的高精度加工需求，本项目拟以高速砂带、柔性接触轮及其它刚性带轮组成的砂带工具系统为研究对象，研究这一刚柔混合体系的非线性动力学特性及调控方法，并探究因工具系统动态形变引起的张力、速度、压力等工艺参量时变、不均匀分布对磨削精度、表面质量及砂带性能劣化的影响机制和规律。. 建立包含柔性带轮、异形轮廓带轮在内的高速砂带横向振动、纵向伸缩、侧向运动三向耦合动力学模型。获得工具系统动力学行为诱导磨削深度变动的基本规律及补偿方法。提出基于工具系统动力学的型面表面粗糙度、残余应力及表面纹理调控方法。得到减缓砂带性能劣化的工具系统动力学优化控制理论和方法。最终实现考虑砂带工具系统动力学行为的砂带磨削质量高精度预报和控制。. 通过项目研究可提高砂带磨削的加工质量及其稳定性，推动高精度砂带磨削新工艺、新装备的发展，具有重要的理论和实际意义。

砂带磨削作为一种柔性磨削手段，具有适应性广、低成本等优点，在精密加工中有广泛的应用。与刚性砂轮是单一构件不同，砂带磨削的工具系统包含柔性砂带、刚性带轮等多个构件通过摩擦耦合在一起。柔性砂带在磨削过程中会呈现出复杂的动力学行为，对磨削质量有很大的影响。. 本项目针对对磨削质量影响最大的砂带侧向运动和砂带横-纵耦合动力学行为开展了研究，具体内容包括：两轮系统砂带侧向运动的解析预测建模和求解方法研究、复杂磨头中砂带侧向运动的有限元分析研究、考虑砂带横-纵耦合的砂带稳态构型研究，并针对目前广泛开展的机器人砂带磨削中存在的机器人几何参数误差标定方法开展了研究。. 提出了带轮倾斜诱导砂带侧向瞬态运动建模及求解方法、分析了带轮倾斜诱导砂带侧向瞬态运动特性，建立了带轮倾斜诱导砂带侧向稳态速度求解封闭模型，为砂带纠偏控制器的设计、分析和评估提供了理论物理模型和理论指导。建立了含复杂轮廓带轮、多轮系统中砂带侧向运动预测的有限元仿真方法，定量分析了带轮轮廓类型、中高量对砂带侧向运动的抑制作用，设计了可变中高带轮，为面向稳定砂带侧向运动的砂带磨头结构设计提供了理论基础。提出了砂带自由段空间构型的建模和求解方法，分析了砂带物理特性、安装条件对空间几何构型及内部张力分布的影响规律，提出了砂带精确打滑条件的迭代计算方法，为利用砂带自由段精密磨抛时的运动补偿和砂带危害性侧滑的防范奠定了理论基础。提出了基于二维测量功能平板的机器人几何参数标定方法，标定成本低，过程简单，具有广阔的应用前景。